Enabling Staged Pressurized Oxy-Combustion (SPOC ......– Update the design of the novel staged, pressurized oxy- combustion (SPOC) system by OEM review – Develop flexible design

© 2018 Electric Power Research Institute, Inc. All rights reserved.© 2015 Electric Power Research Institute, Inc. All rights reserved.

Scott HumePrincipal Technical Leader, EPRI

2018 NETL CO2 Capture Technology Project Review MeetingAugust 14, 2018

Enabling Staged Pressurized Oxy-Combustion (SPOC): Improving Flexibility and

Performance at Reduced CostDE-FE0029087

2© 2018 Electric Power Research Institute, Inc. All rights reserved.© 2015 Electric Power Research Institute, Inc. All rights reserved.

Acknowledgement and DisclaimerAcknowledgementThis material is based upon work supported by the Department of Energy National Energy Technology Laboratory under cooperative award number DE-FE0029087.

Disclaimer“This presentation was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.”


Agenda

Project Overview

Technology Background

Technical Approach

Progress

Plans for Future Development

Questions


Project Overview

Awarded October 2015, 24 month project$1,167m federal funding, $291,800 cost share (20%)EPRI are leading the project alongside Washington University

in St. Louis, American Air Liquide and Doosan BabcockObjectives:

– Update the design of the novel staged, pressurized oxy-combustion (SPOC) system by OEM review

– Develop flexible design concepts utilizing the SPOC system and advanced oxygen supply strategies

– Validate design tools through pilot plant testing


Technology Background – Oxy-Combustion Oxy-combustion technologies typically recycle a portion of the flue gas to reduce the

peak temperatures and increase the resulting gas flow rate, making convective heat transfer easier The fan power needed for flue gas recycle (FGR) increases the overall auxiliary power Atmospheric oxy-combustion necessitates large furnace volumes and cannot utilize fuel

moisture latent heat (low partial pressure of H2O results in low-temperature condensation)

COALO2 FLUE GAS

~80% v/v (d) CO2

STEAM POWER

AIR ASU

FGR

CPU

N2

CO2

Inert Gas Vent

CW

Boiler hardware arrangement similar to conventional air-fired boiler


Compact boiler, enhanced convective heat transfer and lower CO2 compression costs

Technology Background – Oxy-Combustion (cont.)

COAL

O2FLUE GAS~80% v/v (d) CO2

STEAM POWER

AIR ASU CPU

N2

CO2

Inert Gas Vent

Boiler Feedwater

Staged Combustion – most of the oxygen is added to 1st stage but fuel is restricted to deliver appropriate post-combustion temperatures; FGR and gas volume reduced Pressurized Combustion – reduces the size of the combustion system,

eliminates air ingress, allows latent heat from moisture to be recovered at useful temperatures whilst delivering gases to the CPU at elevated pressure, enables easy SOx/NOx removal and restricts radiative heat flux by creating an optically dense medium; FGR is minimized


Technology Background – SPOC

What is “Staged Pressurized Oxy-Combustion” (SPOC)?

Burn fuel incrementally to limit peak temperatures and heat flux levelsAbsorb heat sufficiently to allow next stage combustionMinimal need for FGR, hence low fan power requirementsOperating pressure assures fuel moisture latent heat is captured into the steam cycle

Stage 1 Stage 2 Stage 3 Stage 4

FGRCoal FeedingPressurized

Oxygen

Coal

FGR

Hot Wet FGR

Bottom Ash

Bottom Ash

ASUAir

Nitrogen

Main Steam

Main Steam AshAsh

340°C340°C340°C

593°C

Hot Reheat

593°C

Hot Reheat

593°C

Bottom Ash

Main Steam Ash

340°C

Hot Reheat

593°C

Bottom Ash

Main Steam Ash

Hot Reheat

593°C

To Heat Recovery,Particulate Removal and DCC

BFW 290°C

StageI

EVAP

ECO I

FSH I330°C

420°C

Cold Reheat

FRH I

PRH I

PSH I

Saturated Steam

StageII

EVAP

ECO II

FSH II330°C

420°C

Cold Reheat

FRH II

PRH II

PSH IIStage

III EVAP

ECO III

FSH III330°C

420°C

Cold Reheat

FRH III

PRH III

PSH III

Saturated Steam

Saturated Steam

StageIV

EVAP

ECO IV

FSH IV330°C

420°C

Cold Reheat

FRH IV

PRH IV

PSH IV

Saturated Steam


Technical ApproachTask Description Sub-tasksTask 2 Concept review and configuration

optimizationDesign BasisBoiler OEM review of prior workDeveloped risk matrix Upgraded OEM boiler performance model for SPOC conditionsConducted heating surface sizing exercise for 550MWe scaleDefine boiler concept design, assess costs

Task 3 System integration with steam cycle

Model NETL baseline case B12AAssess heat recovery opportunitiesAuxiliary power of SPOC system

Task 4 Turndown and flexibility Options for enhanced turndownOxygen supply flexibility

Task 5 Combustor performance testing Upgrade pilot plant for target pressure operationCarry out full load and part load testing to recommended conditions

Task 6 Economics CAPEX assessment, OPEX and LCOE


Progress: Project Schedule Task 2 – SPOC concept review (complete) Tasks 3, 4 & 5 – Integration, flexibility and testing (ongoing) Task 6 – Economics (to be initiated)

Boiler design activity minor delay due to workshop scheduling

Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr

Task 1.0: Project Management and Planning 11/1/2016 10/31/2018 Subtask 1.1: Project and Risk Management 11/1/2016 10/31/2018 M1 Subtask 1.2: Financial Reporting 11/1/2016 10/31/2018 Q Q Q Q Q Q Q Subtask 1.3: Project Reporting 11/1/2016 10/31/2018 K, M2 K, M2 Subtask 1.4: Technology Transfer/Exchange 11/1/2016 10/31/2018 Q Q Q Q Q Q QTask 2.0: Concept Review and Configuration Optimization 3/1/2017 3/31/2018 Subtask 2.1: Design Basis Development 3/1/2017 4/31/2017 M3 M3 Subtask 2.2: SPOC Boiler Concept Review 4/1/2017 8/31/2017 S Subtask 2.3: Definition of Optimized Arrangement for 550-MWe Scale 6/1/2017 3/31/2018 M4 M4Task 3.0: Detailed Integration of SPOC with the Steam Cycle 10/1/2017 8/31/2018 Subtask 3.1: Steam Generator Performance 10/1/2017 3/31/2018 Subtask 3.2: CFD Modeling 12/1/2017 5/31/2018 Subtask 3.3: Steam Turbine Performance 3/1/2018 7/31/2018 Subtask 3.4: Oxygen Supply Energy Requirements 5/1/2018 8/31/2018Task 4.0: Turndown and Flexibility 1/1/2018 5/31/2018 Subtask 4.1: Steam Generator Turndown 1/1/2018 5/31/2018 Subtask 4.2: Steam Generator Performance 1/1/2018 5/31/2018 Subtask 4.3: Oxygen Supply Flexibility 1/1/2018 5/31/2018 S, M5 S, M5Task 5.0: Combustor Performance Testing 12/1/2016 9/30/2018 Subtask 5.1: Retrofit of 100-kWth Pressurized Oxy-Combustor 12/1/2016 4/30/2018 M6,D Subtask 5.2: Experimental Determination of Combustion Domains 5/1/2018 3/31/2018 Subtask 5.3: Measurement of Heat Flux, Composition, and Temperatures 8/1/2017 9/30/2018Task 6.0: Economics 5/1/2018 10/31/2018 Subtask 6.1: SPOC System Total Overnight Capital 5/1/2018 7/31/2018 Subtask 6.2: ASU Overnight Capital 7/1/2018 9/30/2018 Subtask 6.3: COE Assessment 9/1/2018 10/31/2018 F, M7

Task Name Start Date End Date 2016 2017 2018 2019

FY 2017 FY 2018 FY 2019


Task 2 – OEM Concept Review The previously developed SPOC boiler concept

was reviewed against OEM boiler design requirements

Areas of particular focus were: Layout Vessel Arrangement and Sizing Burner Design Fuel Selection and Fuel Handling Particulate Removal Ash Management and Ash Handling

Risk matrix developed (with potential mitigations)


Task 2 – Risk Mitigation

Revised design:– Combustor vessel with steam cooled walls

and no heating surface in the gas path– Transition to upward flowing ‘convective’

sections – allowing for ash and slag management

– Cross flow heat transfer, substantial heat transfer surface

A workshop was held to develop the concept further


Task 2 – Original SPOC Concept

Each stage has unique

performance requirements

A B D F H

C E G I

J

K

42% O2 29% O2 20% O2 15% O2

52 kg/s

100% O2

23 kg/s

100% O2

23 kg/s

100% O2

23.6 kg/s

100% O2

150 kg/s

19% O2

192 kg/s

12% O2

234 kg/s

7% O2

277 kg/s

3% O2

79 kg/s

3% O2

19.3 kg/s

100% Fuel

19.3 kg/s

100% Fuel

19.3 kg/s

100% Fuel

19.3 kg/s

100% Fuel

L

A B C D E F G H I J K

Total Flow (kg/s) 121.6 52 150 23 192 23 234 23.6 277 79 198

[O2] (% v.) 100 100 17 100 10 100 6 100 3 3 3

[CO2] (% v.) 0 0 48 0 52 0 54 0 56 56 56

[H2O] (% v.) 0 0 35 0 38 0 40 0 41 41 41


Task 2 – Revised SPOC ArrangementA

B E H K

C F I L

D G J

M1 M2 M3

N

O

30% O278 kg/s

3% O2

30 kg/s

100% O2

30 kg/s

100% O2

30 kg/s

100% O2

30 kg/s

100% O2

78 kg/s

3% O2

78 kg/s

3% O2

78 kg/s

3% O2

131 kg/s

3% O2

131 kg/s

3% O2

131 kg/s

3% O2

131 kg/s

3% O2

30% O2 30% O2 30% O2

P

19.3 kg/s

100% Fuel

19.3 kg/s

100% Fuel

19.3 kg/s

100% Fuel19.3 kg/s

100% Fuel

53 kg/s

3% O2

53 kg/s

3% O2

53 kg/s

3% O2213 kg/s

3% O2

A B C D E F G H I J K L M1 M2 M3 N O

Total Flow (kg/s) 122 30.4 131 77.8 30.4 131 77.8 30.4 131 77.8 30.4 131 53.2 53.2 53.2 53.2 213

[O2] (% v.) 100 100 3 3 100 3 3 100 3 3 100 3 3 3 3 3 3

[CO2] (% v.) 0 0 56 56 0 56 56 0 56 56 0 56 56 56 56 56 56

[H2O] (% v.) 0 0 41 41 0 41 41 0 41 41 0 41 41 41 41 41 41

Identical Stages - lower development

costs


0

500

0 10 20 30 40 50 60

Q(k

w/m

2 )

x(m)

Task 2 – Combustion – Long conical design PRB coal; 385MW; 30%/70% of O2/CO2; Particle size: 40% 1.6~2.0 mm, 60% 10~200 μm.

Temperature contour (°C)

Total surface heat flux (kW/m2)

Complex furnace tube geometry needed in upper sections

Drawing to scale

3.8

m


0

500

0 10 20 30 40 50 60

Q(k

w/m

2 )

x(m)0

500

0 10 20 30 40 50 60

Q(k

w/m

2 )

x(m)

2.3 – Combustion – Revised design Same conditions as previous case except particle size is 50% 1.4~1.8 mm, 50% 10~200 μm

Temperature contour (°C)

Total surface heat flux (kW/m2)

Simplified SPOC for reduced capital costs and lower peak heat flux

Drawing to scale

3.8

m


Task 2 – 550MWe Design

Aim to reduce construction costsSingle boiler design across all stagesModular and ground transportable Sequential gas bed conceptHot FGR ensures stage 1 identical to subsequent stagesSteam/water equally shared across all stages

– Mass flux / geometry / tube selection– Cage design, accommodation of headers/supplies/risers

Identical furnace and boiler stages reduces cost and complexity


COMBUSTOR MODULE

CONVECTIVE MODULE

PSH

FRH

FSH

SSH

PRH

ECO

‘WATERWALLS’ (Circular

Membrane)

Steam Cooled Cage (Box section)

Task 2 – Module Design

Two pressure vessels needed for a single SPOC ‘stage’Combustor module cooled

with evaporative surface due to high incident heat fluxDirection change at base to

aid furnace ash dropoutConvective pass headers

contained within PV cavities (minimize penetrations)


Task 2 –Combustor Module Concept

Sized based on WUSTL combustion performance predictionsEvaporator based on once-through,

vertical tube membrane wall arrangementTop and bottom sections refractory

lined


Task 2 –Convective Module ConceptMembrane walls,

square profile Internal sub-headersPlenum at base to

assist ash dropout Inert CO2 gas added

to cool pressure vessel In-situ cleaning


Task 3 – Integration with steam cycle

NETL baseline case S12A modeledAssessment of heat recovery available34 MWth available at sufficient

temperature for HP feedwater bypass136 MWth available at lower

temperatures from DCC/acid gas removal columnCorrosion resistant materials needed

due to high acid dew point at pressureLow temperature heat available sufficient to eliminate LP feedwater heaters


Task 4 – FlexibilityStage Bypass Potential

– at reduced firing rates on proceeding stages, full bypass of subsequent stages is possible with Concept 3 arrangement

– NFPA-85 compliance, purge flow before stage restart Increased FGR at low load

– Improved convective/radiative balancingAir Separation Unit

– Storage of air inventory to allow MAC ‘deferment’– Reduced LOx storage, maintain 8 hour startup oxygen

supplyStaged system delivers high turndown potential


Task 5 – WUSTL Pressurized Combustion Facility

Multiple load cases planned for numerical model validation

• Pressures up to 15 barg• Thermal input up to 100 kW• Solid and gaseous fuel testing capability• Full view of near-burner (flame) region

• Diagnostics include: Temperature profile High Speed Camera Heat Flux Particle / gas sampling and ELPI, CEM Laser transmission for soot/ash measurement Fourier-transform infrared spectroscopy (FTIR)

• Ability to test multiple burners Two types of burner configurations tested

burnernozzle

quartz section







burnernozzle

quartz section







burnernozzle

quartz section

Camera

Cooling Coils

Lights

Sample Tubeignitor

laser output on 2-D

translationstage


Task 5 – Firing experience and validation

Qualitative agreement between experiments and simulations achieved in terms of flame shape and flow field

Coal-O2/CO2

Experiments from 1 bar to 15 bar conducted at WUSTL

show similar characteristics.

HS Camera VideoVideo LES Simulation

Quartz wall




Coal-O2/CO2




Quartz wall




Coal-O2/CO2




Quartz wall




Coal-O2/CO2




Quartz wall




Coal-O2/CO2




Quartz wall




Coal-O2/CO2




Quartz wall


Task 5 – Operation: 100% coal combustion at 15 bar

Results used to validate CFD models for full scale application

• Stable flame without methane support

• No CO and soot emission detected

• Complete burnout with 3% oxygen concentration

Full Load (100 kWth) Part Load (50 kWth) Ash analysis


Plans for future development

Validation of modeling from test resultsReduction of ASU auxiliary power and

thermal integrationFlexibility opportunities for oxygen supplyCost analysis of 550MW concept design


Questions


Together…Shaping the Future of ElectricityTogether…Shaping the Future of Electricity

Documents

Enabling Staged Pressurized Oxy-Combustion (SPOC ......– Update the design of the novel staged, pressurized oxy- combustion (SPOC) system by OEM review – Develop flexible design